Handheld rotary tool

ABSTRACT

A rotary tool is provided with a head section that is selectively pivotable at a plurality of positions between an orientation where the head section is in-line with a body section to an orientation where the head section is perpendicular to the body section. The rotary tool can also swivel about an arc of 360 degrees.

BACKGROUND

The present invention relates to power tools, and in particular to arotary tool with a head section that can pivot with respect to the bodyof the tool. Additionally, the present invention relates to a rotarytool with a head section that can rotate with respect to the bodysection of the tool. The present invention also contemplates a rotarytool having a head section that can pivot and rotate with respect to thebody section. The tool of the present invention improves on previousdesigns because it includes a head section that can pivot and/or rotatewith respect to a body section with the motor positioned within the bodysection. Previous rotary tool designs included a motor that was locatedwithin the head section, which caused the head section to besignificantly larger than the head section of the present invention,which limited the operability of the previous tools in tight spaces.

BRIEF SUMMARY

The present invention provides a rotary tool operable in at least twopositions. The rotary tool includes a transmission with an input end andan output end, a body section housing the input end of the transmissionand a motor that is connected to the input end of the transmission. Thebody section includes a longitudinal axis. The rotary tool additionallyincludes a head section housing the output end of the transmission and aspindle that is connected to the output end of the transmission. Therotary tool also includes a lock to selectively retain the head sectionin a selected orientation with respect to the body section along a pivotaxis, wherein the head section is capable of being retainedsubstantially orthogonally to the longitudinal axis of the body section.

The rotary tool may include a head section that can rotate, or swivelabout the longitudinal axis of the body section. A body section isprovided with a gearbox housing, a sleeve that surrounds a top portionof the gearbox housing and that moves axially along the gearbox housing.A rotatable cap surrounds the sleeve to selectively cause engagement ofthe sleeve and the gearbox housing. The head section is prevented fromrotating with respect the body section when the sleeve engages thegearbox housing.

Advantages of the present invention will become more apparent to thoseskilled in the art from the following description of the preferredembodiments of the invention that have been shown and described by wayof illustration. As will be realized, the invention is capable of otherand different embodiments, and its details are capable of modificationin various respects. Accordingly, the drawings and description are to beregarded as illustrative in nature and not as restrictive.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view of one embodiment of the rotary tool, showing thehead section of the tool in-line with the body section of the tool ofthe present invention.

FIG. 2 is a side view of the tool of FIG. 1, with the head sectionperpendicular to the body section of the tool.

FIG. 3 is an exploded view of the tool of FIG. 1, showing the componentsaligned with the head section in-line with the body section.

FIG. 4 is an exploded view of the tool of FIG. 1.

FIG. 5 is a cross-sectional view of the tool of FIG. 1, showing thecomponents of the locking mechanism in the locked position.

FIG. 6 is a cross-sectional view FIG. 5 in the unlocked position.

FIG. 7 is a perspective view of a second embodiment of the rotary toolof the present invention, showing the head section of the tool in-linewith the body section of the tool.

FIG. 8 is the view of FIG. 7, showing the head section of the toolperpendicular to the body section of the tool.

FIG. 9 is a partial exploded view of the tool of FIG. 7.

FIG. 9 a is a perspective view of the pivot housing.

FIG. 9 b is a perspective view of the second housing cover.

FIG. 10 is a side view of the pivot housing and the cover section whenthe head section of the tool is in-line with the body section of thetool.

FIG. 11 is a side view of the pivot housing, cover section, and middlehousing cover when the head section is in-line with the body section ofthe tool.

FIG. 12 is a side view of FIG. 10, of the pivot housing and the coversection when the head section is at a first oblique angle with respectto the body section of the tool.

FIG. 13 is a side view of FIG. 11, of the pivot housing, cover section,and middle housing cover when the head section is at a first obliqueangle with respect to the body section.

FIG. 14 is a side view of FIG. 10, of the pivot housing and the coversection when the head section is at a second oblique angle with respectto the body section.

FIG. 15 is the view of FIG. 11, of the pivot housing, cover section, andmiddle housing cover when the head section is at a second oblique anglewith respect to the body section.

FIG. 16 is the view of FIG. 10, of the pivot housing and the coversection when the head section is perpendicular to the body section.

FIG. 17 is the view of FIG. 11, of the pivot housing, cover section, andmiddle housing cover when the head section is perpendicular to the bodysection.

FIG. 18 is a perspective view of an alternate embodiment of the pivothousing.

FIG. 19 is a perspective view of tool of FIG. 18, with the lock buttonremoved to show the head section in-line with the body section.

FIG. 20 is the view of FIG. 19, showing the head section at a forty fivedegree angle with respect to the body section.

FIG. 21 is the view of FIG. 19, showing the head section perpendicularto the body section.

FIG. 22 is an exploded view of the a third embodiment of the handheldrotary tool.

FIG. 23 is a perspective view of the tool of FIG. 22, showing thegearbox housing connected to the universal joint.

FIG. 24 is a perspective view of the tool of FIG. 22, showing the lockhousing.

FIG. 25 is a perspective view of the tool of FIG. 22, showing the lockhousing.

FIG. 26 is a perspective view of the tool of FIG. 22, showing the upperswivel cap.

FIG. 27 is a perspective view of an alternate embodiment of the pivothousing and the lock housing.

DETAILED DESCRIPTION

Referring now to FIGS. 1-6, a handheld pivotable tool 10 according tothe present invention is shown. As an example, the handheld pivotabletool 10 can be a handheld drill or a handheld impact driver. FIGS. 3 and4 are exploded views of the components of the handheld pivotable tool10. The handheld pivotable tool 10 has a head section 12 that rotatablymoves an output tool or bit. The head section 12 can freely pivot abouta body section 14 that is held by a user during operation. The headsection 12 may be retained in one position where the longitudinal axis13 a of the head section 12 is aligned along the longitudinal axis 13 ofthe body section 14. The head section 12 may also be selectively pivotedto positions other than aligned with the longitudinal axis 13.Desirably, the head section 12 can be pivoted about a pivot axis 13 b(FIGS. 3 and 4) to a plurality of positions between an orientation wherethe head section 12 is in-line with the body section 14 and anorientation where the head section 12 is orthogonal to the body section14. For example, FIG. 20 shows the head section 12 at a 45 degree anglewith respect to the body section 14. In other embodiments, the headsection 12 can be retained at other angles with respect to the bodysection 14. The handheld pivotable tool 10 is provided with a lockingmechanism 19 to retain the head section 12 in the selected position withrespect to the body section 14.

In embodiments where the handheld pivotable tool 10 is an impact driver,the impact mechanism can either be located inside the body section 14behind an input end of the transmission or universal joint 80, or in thehead section 12 engaging with the output end of the universal joint 80behind the spindle 124.

The pivotable handheld pivotable tool 10 includes a carrier 20, agearbox housing 40, a lock housing 60, a universal joint 80, a pivothousing 100, and a spindle lock housing 120. The locking mechanism 19includes a lock housing 60, a pivot housing 100, a block 108, and a lockbutton 110. Apertures 68, 106 formed in the lock housing 60 and thepivot housing 100, respectively, receive the lock button 110 thatretains the block 108 within the apertures 68, 106.

The body section 14 of the handheld rotary tool 10 includes the motor17, the gearbox 18, the carrier 20, the gearbox housing 40, and the lockhousing 60. The body section 14 also retains a rear section 83 of theuniversal joint 80. In other embodiments, the handheld rotary tool 10can be formed without a gearbox 18 such that the output spindle 124rotates at the same angular velocity as the motor shaft 17 a. In theseembodiments, the output shaft 17 a of the motor 17 engages directly withthe carrier 20, or similar structure known to those in the art to accepttorque from a motor and transfer the torque to the remaining members ofthe handheld rotary tool 10. In these embodiments, the tool is stillformed with a structure similar to the gearbox housing 40. Specifically,the tool in these embodiments includes a structure that includes atleast the shoulder 44 and the neck 46 of the gearbox housing 40described herein including all of the structure that is discussed belowthat is a part of the shoulder 44 and the neck 46 of the gearbox housing40. The term “gearbox housing” is used throughout the specification andclaims for the sake of simplicity. It should be understood that the term“gearbox housing” is the name for the structure shown as element 40, butshould not be understood to require that the structure 40 enclose andsupport a speed reduction gearbox nor that the use of a speed reductiongearbox is a required element of the embodiments or the claims.

It is contemplated to provide a control mechanism within the bodysection to allow the user to control the output torque of the handheldpivotable tool 10. For example, as shown in FIG. 1, a clutch 16 isincluded in the body section 14 between the gearbox housing 40 and thelock housing 60 to control the transfer of torque between the gear train18 and the carrier 20.

The head section 12 includes a pivot housing 100 and a spindle lockhousing 120, which supports a spindle lock mechanism (not shown). Thespindle lock housing 120 receives a front section 92 of the universaljoint 80. The spindle lock housing 120 further includes an outputspindle 124 with a hexagonal collet to accept an output tool (notshown). As is discussed in detail below, the head section 12 ismaintained in a selected position with respect to the body section 14with a connection between the lock housing 60 and the pivot housing 100.The head section further includes a bearing 130, which is mounted on thefront section 92 of the universal joint 80, discussed below.

The carrier 20 is provided within the body section 14 and is enclosedwithin the gearbox housing 40 (along with portions of the gear train18). The carrier 20 is disc-shaped with a plurality of posts 22extending from the rear surface of the discs and a hollow cylinder 24extending from the front surface. Each of the posts 22 are preferablyinserted into a center aperture of a planet gear 18 a that is includedwithin a planetary gear train 18. Therefore, the carrier 20 rotatesalong with the rotation of the planet gears, which rotate about aninternal sun gear 18 b, normally attached to an output shaft 17 a of amotor 17. The planetary gear train 18 may include multiple stages.Therefore, the carrier 20 rotates within the body section 14 based onthe rotation of the motor 17. The carrier 20 is retained within a bodysection 42 of the gearbox housing 40, with the front surface of thecarrier located in close vicinity to the rear surface of the bodysection 42. When the carrier 20 is in this position, the hollow cylinder24 extends into a shoulder portion 44 of the gearbox housing 40.

The hollow cylinder 24 of the carrier 20 is formed with an aperture 25through which the rear end 83 of the rear section 82 of the universaljoint 80 is inserted. Preferably, the aperture 25 and rear end 83 areformed to prohibit relative rotation between the two when the end 83 isinserted into the aperture 25. The aperture 25 and the rear end 83 mayhave complementary shapes. In some embodiments, the rear end 83 and theaperture 25 are each formed as a “D” or a similar shape to preventrelative rotation between the universal joint 80 and carrier 20.Upstream of the carrier 20, the rear section 82 of the universal gear isrotationally supported by a needle roller bearing 26 that is housedwithin the shoulder portion 44 of the gearbox housing 40. Additionally,the rear section 82 of the universal joint 80 can be rotationallysupported by a bushing 27. The universal joint 80 therefore accepts thetorque transferred to the carrier 20 by the motor 17 and the gear train18 and allows the torque to be transferred to the head section 12.

The gearbox housing 40 is formed from three sections, the body section42, the shoulder 44, and the neck 46. The body section 42 is formed withthe largest circumference and is formed to house or at least partiallyenclose the front end of the motor 17, the gear train 18, and thecarrier 20, with the hollow cylinder 24 of the carrier 20 extending intothe shoulder 44.

The neck 46 of the gearbox housing 40 extends from the front end of theshoulder 44 along the same axis as the shoulder 44 and body section 42.The rear section 82 of the universal joint extends from its connectionwith the carrier within the shoulder 44 into the neck 46. The neck 46preferably includes a U-shaped cutout 48 formed along one side of theneck 46 that extends from the forward surface of the neck 46 toward, butnot reaching, the shoulder 44. The universal joint 80 is positioned withrespect to the neck 46 such that a center section 88 of the universaljoint 80 pivots from a position where the center section 88 is in linewith the rear section 82 of the universal joint 80 to a position wherethe center section 88 is at an oblique angle with respect to the rearsection 82. When the center section 88 is not positioned along the sameline as the rear section 82, the center section 88 extends through theU-shaped cutout 48. In other embodiments, other structures to movablysupport the rear section 83 of the universal joint 80 may be used.

The neck 46 additionally includes two through holes 50 that are alongthe same axis on the walls of the neck 46. The holes 50 are positionedto accept a press fit connector 54 with the lock housing 60 to mount thelock housing 60 onto the neck 46, which prevents any relative motionbetween the lock housing 60 and the gearbox housing 40. When the lockhousing 60 is connected to the neck, the bottom surface of the lockhousing 60 rests on a ledge 45 between the shoulder and the neck 46.

The lock housing 60 includes a U-shaped aperture 64 that issubstantially the same shape and in the same location as the U-shapedaperture 48 in the neck 46. Similar to the U-shaped aperture 48 in thegearbox housing 40, the U-shaped aperture 64 in the lock housing 60provides an opening to allow the center section 88 of the universaljoint 80 to extend through the circumference of the lock housing 60. Thelock housing 60 also includes a round projection 66 that extends fromthe outer circumference of the lock housing 60. The projection 66 has acenterline that is perpendicular to a plane that bisects the U-shapedaperture 64. Preferably, the centerline of the projection 66 is alongthe pivot axis 13 b that the head section 12 pivots with respect to thebody section 14. The projection 66 includes a recess 68 (or aperture)that blindly extends into the projection 66. The recess 68 has a shapeto receive a portion of the block 108, as further described below. Thelock housing 60 has a second projection 70 that extends along the sameaxis as the projection 66 and extends from the opposite external surfaceof the lock housing 60. The second projection 70 is round and ispreferably the same height as the projection 66.

In other embodiments, the lock housing 60 can be formed integral withthe gearbox housing 40. In this embodiment, the neck 46 of the gearboxhousing 40 is formed in the shape of the lock housing 60, including theprojection 66 with the recess 68 and the opposite second projection 70.In embodiments where the gearbox housing 40 also forms the lock housing60, the U-shaped aperture 48 in the neck 46 is integral with theU-shaped aperture 64 in the lock housing.

As noted above, the universal joint 80 includes three sections, a rearsection 82, a center section 88, and a front section 92. The rearsection 82 is mounted to the carrier 20 with an end 83 having a shapecomplementary to the aperture 25 in the carrier 20 to cause the rearsection 82 to rotate with the rotation of the carrier 20. Each of thesections 82, 88, 92 are connected together with pins 85 and a center hub(not shown). The pins 85 and the center hub allow the transfer of torquefrom the rear section 82 to the center section 88, and from the centersection 88 to the front section 92, so the front section 92 rotates whenthe rear section 82 rotates. The pins 85 and the center hub also allowrelative pivoting with respect to each of the sections. While the rearsection 82 is constrained from pivoting with respect to the body section14 by the connection between the rear section 82 and the carrier 20, thecenter section 88 can pivot with respect to the rear section 82.Similarly, the front section 92 can pivot with respect to the centersection 88. Also, as discussed above, the U-shaped apertures in the neck46 of the gearbox housing 40 and the lock housing 60 (48, 64) permitclearance for the center section 88 and the front section 92 to pivotwithin the tool. This pivoting motion of the center and front sections88, 92 allows the head section 12 to pivot with respect to the bodysection 14 along the pivot axis 13 b.

The front section 92 of the universal joint 80 may be integrally formedwith a spindle lock housing 120 or the two components may be formedseparately and attached together by structure that is known to those ofskill in the art. The spindle lock housing 120 is rotatably supported bya bearing 130 that is mounted within the pivot housing 100.

As best seen in FIG. 3, the pivot housing 100 is formed from at leasttwo clamshell halves. The pivot housing 100 surrounds the rear portion126 of the spindle lock housing 120, as well as the universal joint 80,the lock housing 60, and a portion of the neck 46 of the gearbox housing40. When assembled, in this embodiment, the pivot housing 100 isgenerally cylindrical, with a removed section 102 that corresponds tothe U-shaped apertures 48, 64 in the neck 46 and lock housing 60,respectively. The removed section 102 provides clearance between thepivot housing 100 and the components that form the body section 14 sothat the head section 12 can pivot with respect to the body section 14.

The pivot housing 100 includes a recessed section 104 along an outersurface of the pivot housing 100. The recessed section 104 may have anysuitable shape, but in one embodiment, it is circular. A centerline ofthe recessed section 104 is perpendicular to a plane that bisects theremoved section 102. Preferably, the centerline of the recessed section104 is positioned co-linear with the pivot axis 13 b when the pivothousing 100 is positioned with respect to the lock housing 60. Anaperture 106 is formed in the recessed section 104 with the center ofthe aperture 106 being along the centerline of the recessed section 104.In some embodiments (shown in FIGS. 3 and 4), the aperture 106 is formedin a cross shape, with four legs 107 radiating from the centerline andperpendicular to each other. In other embodiments (shown in FIGS. 18-21)the aperture 106 is formed with eight legs 107 radiating from thecenterline and at a forty-five degree angle from the neighboring legs107. In either embodiment, the legs 107 may have the same length. Therecessed section 104 further includes a plurality of holes 112 along theperiphery of the aperture 106. The holes 112 may be rectangular.

In another embodiment shown in FIG. 27, the aperture 106 may be replacedwith an arcuate track 106 a with a center point of the arcuate track 106a located at the pivot axis 13 b. In this embodiment, the recess 68 onthe lock housing 60 is formed at the same distance R from the pivot axis13 b as the radius R of the arcuate track 106 a, such that the recess 68is in line with the track 106 a throughout the range of motion of thehead section 12 with respect to the body section 14.

It is contemplated that the aperture can be formed with a structureother than four or more legs. Desirably, the aperture will have a shapecomplementary to the shape of the lock block 108, as described below andalso will have a shape to permit a plurality of selective discreteorientations of the head section 12 with respect to the body section 14.In other embodiments of the lock block 108, the aperture 106, and therecess 68 can be formed of alternate, non-circular, shapes such thatwhen the lock block 108 engages both the aperture 106 and the recess 68,the head section 12 cannot pivot with respect to the body section 14.For example, the lock block 108, aperture 106, and the recess 68 caneach be formed as a square, a triangle, a pentagon, a hexagon, etc.

The pivot housing 100 additionally includes a hollow, circularprojection 118 that extends from the inner surface of the pivot housing100 toward the centerline of the pivot housing 100. The circularprojection 118 extends along the same centerline as the aperture 106 andis formed with an inner diameter slightly larger than the secondprojection 70 that extends from the lock housing 60. When the pivothousing 100 is assembled to surround the lock housing 60, the connectionbetween the second projection 70 of the lock housing 60 and the circularprojection 118 of the pivot housing 100 provides a stable rotationalconnection between the pivot housing 100 and the lock housing 60.

As best shown in FIG. 3, a lock block 108 is provided with a shapecomplementary to that of recess 68 of the lock housing 60. In oneembodiment, the lock block 108 is formed as a cross, or a plus symbol(+), with four arms 109 that extend from the center of the lock block108 and are perpendicular to each other. The height of the lock block108 is slightly smaller than the length of the projection 68 from thelock housing 60 and is the same depth as the recess 68 of the lockhousing 60. When the handheld pivotable tool 10 is assembled, the lockblock 108 is inserted into the aperture 106 of the pivot housing 100 andfurther into the recess 68 of the lock housing 60. A spring 116 (FIGS. 5and 6) is provided between the bottom of the recess 68 in the lockhousing 60 and the bottom of the lock block 108, to bias the lock block108 upwards away from the bottom of the recess 68 in the lock housing60.

Normally, as shown in FIG. 5, the spring 116 biases the lock block 108into a position where the top portion of the lock block 108 extends intothe aperture 106 within the pivot housing 100 and the bottom portion ofthe lock block 108 extends into the recess 68 within the pivot housing60. In this situation, the pivot housing 100 cannot rotate or move withrespect to the lock housing 60 because the arms 109 of the lock block108 are inserted within the four of the mutually perpendicular legs 107of the aperture 106 in the pivot housing 100, as well as within the legs69 of the recess 68 of the lock housing 60.

In the embodiments shown in FIGS. 3 and 4, with a cross-shaped aperture106 on the pivot housing 100, the pivot housing 100 (and output tool)can be retained in a position where it is along the same line as thebody section 14 of the handheld pivotable tool 10 (FIG. 3) and in aposition where the pivot section 100 (and output tool) is perpendicularto the body section 14 of the handheld pivotable tool 10 (FIG. 4). Inthe embodiments shown in FIGS. 18-21, the aperture 106 in the pivothousing is formed with eight legs 107, the pivot housing 100 (and outputtool) can be retained in a position where the pivot housing 100 iseither along the same line as the body section 14 (FIG. 19), at aforty-five degree angle to the body section 14 (FIG. 20), orperpendicular to the body section 14 (FIG. 21).

The lock block 108 is moveably retained in its position inserted withinat least the recess 68 of the lock housing (and when biased upward bythe spring 116 within the aperture 106 of the pivot housing) by a lockbutton 110. The lock button 110 includes a center projection 110 a (bestshown in FIGS. 5 and 6) that is sized to fit within the center of theaperture 106 in the pivot housing 100. The lock button 110 also includesa plurality of legs 111 that extend in the same direction as the centerprojection 110 a that are inserted into the plurality of apertures 112in the recessed section 104 of the pivot housing 100. The legs 111 eachpreferably include outwardly facing tabs 111 a that maintain the legs111 inserted within the apertures 112.

Normally, as shown in FIG. 5, when no inward force is applied to thebutton 110, the biasing force of the spring 116 pushes the lock block106 outward to contact the center projection 110 a of the lock button110. As discussed above, in this position, the lock block 108 extendswithin the aperture 106 in the pivot housing 100 and the recess 68 inthe lock housing 60, to prevent relative motion between the head section12 and the body section 14. As shown in FIG. 6, when the lock button 110is pushed inward, the center projection 110 a urges the lock block 108inward against the biasing force of the spring 116 until it no longer isinserted within the aperture 106 in the pivot housing 100. In thisorientation, the pivot housing 100 (and the head section 12) is free topivot with respect to the body section 14 of the handheld pivotable tool10. When the lock button 110 is released, the spring 116 urges the lockblock 108 (and the lock button 110) outward until the lock block 108again is inserted within the aperture 106 in the pivot housing 100 toretain the pivot housing 100 and head section 12 in the selectedposition with respect to the body section 14.

If the pivot housing 100 is not either in-line, at a forty-five degreeangle (in embodiments shown in FIGS. 18-21), or perpendicular withrespect to the body section 14 the lock block 108 will not enter theaperture 106 in the pivot housing due to the specific shapes of the lockblock 108 and aperture 106 in the pivot housing 100. The tool can bepivoted until it reaches one of these positions to allow the lock block108 to again move into the aperture 106.

In the embodiment shown in FIG. 27, and as partially discussed above, anarcuate slot 106 a is provided instead of the aperture 106 on the pivothousing 100, and the lock button 110 is formed with legs 111 that ridewithin tracks 113 in the pivot housing 100. The lock button 110 has aprojection (not shown in FIG. 27 but similar to the projection 110 ashown in FIGS. 5 and 6) that engages the top portion of the lock block108. The lock block 108 is sized so that it can be inserted intoenlarged portions 106 b at predetermined positions on the arcuate slot106 a (i.e. positions where the head section 12 will be retained withrespect to the body section 14). FIG. 27 shows the enlarged portions 106b formed at the extreme ends of the arcuate slot 106 a. In otherembodiments, the arcuate slot 106 a can include enlarged portions 106 bat other positions within the arcuate slot 106 a. To change theorientation of the head section 12 with respect to the body section 14,the lock button 110 is pressed against the biasing force of the spring116, so that the lock block 108 moves out of engagement with the arcuateslot 106 a, to allow the head section 12 to be pivoted with respect tothe body section. When the tool is in the required orientation, the lockbutton 110 is released and the lock block again engages the arcuate slot106 a within the pivot housing to retain the tool in the selectedorientation.

A second embodiment of the handheld pivotable tool 10 is shown in FIGS.7-17. This handheld pivotable tool 10 includes all of the structurediscussed in the embodiment shown in FIGS. 1-6 (and 18-21) above,including the structure that encloses and protects the internalcomponents of the lock housing 60, pivot housing 100, and universaljoint 80 throughout the range of motion of the head section 12 withrespect to the body section 14. This embodiment however, includes asecond housing cover 140 and a cover piece 160. The embodiments shown inFIGS. 7-17 include a pivot housing 100 that has a spherical profile,instead of the cylindrical pivot housing 100 shown in FIGS. 1-6. Thestructure disclosed below can be modified to include the second housingcover 140 and cover piece 160 in embodiments where the pivot housing 100has a cylindrical profile. Similarly, the embodiments shown in FIGS. 1-6and discussed above can be modified to form the pivot housing 100 with aspherical profile, as shown in FIGS. 18-21.

The second housing cover 140 is formed from two clamshell halves (aslotted piece 142 and a unslotted piece 144) that are connected togetherto surround a majority of the lock housing 60 and allow the motion ofthe universal joint 80 discussed above for the head section 12 to pivotwith respect to the body section 14. The second housing cover 140 issurrounded by the pivot housing 100. The clamshell halves of the secondhousing cover 140 are connected along a plane that is perpendicular tothe plane formed by the edges of the clamshell halves of the pivothousing, and also extends through a centerline of the body section 14 ofthe handheld pivotable tool 10.

As best seen in FIG. 9, the second housing cover 140 forms two circularholes 141, 143 with the centerline of each extending through the planeformed by the connection between the clamshell halves of the secondhousing cover 140. The holes 141, 143 are positioned to allow theprojections 66, 70 of the lock housing 60 to extend through. The secondhousing cover 140 further includes a bottom aperture 148 a, which issized to allow the second housing cover 140 to surround the lock housing60 and a top aperture 148 b. The top aperture 148 b is sized to allowthe second housing cover 140 to surround the lock housing 60, and alsoto allow the universal joint 80 to pivot with respect to the bodysection 14.

The cover section 160 is formed as a curved plate and is insertedbetween the second housing cover 140 and the pivot housing 100 to coverany exposed regions of either the lock housing 60 or the universal joint80 during the range of motion of the handheld pivotable tool 10. Themotion of the cover section 160 is constrained by the internal structureof the pivot housing 100 and the external structure of the secondhousing cover 140. Specifically, as shown in FIG. 9 a, the pivot housing100 is formed with interior sidewalls 208 that are formed with anarcuate slot 210. The arcuate slot 210 has an arc length greater thanthe ninety degree range of motion of the head section 12 of the tool.The slot 210 includes a first face 212 and a second face 214. (Theopposite clamshell half of the pivot housing 100 has a similar arcuateslot with a first and second face, not shown). When the handheldpivotable tool 10 is assembled, the cover section 160 rides within thearcuate slot 210 and its range of motion is partially determined by thepositions of the first face 212 and the second face 214.

The slotted piece 142 of the second housing cover 140 includes a pair oftop faces 152 and a pair of bottom faces 154 (best shown in FIG. 9 b).The top and bottom faces 152, 154 are formed at the intersection betweena top and bottom section 145, 146 near the edges where the slotted piece142 contacts the edge of the unslotted piece 144. The top and bottomsections 145, 146 are formed at a first diameter, and the middle section147 (in the region between the edge sections) is formed with a second,smaller diameter. When the handheld pivotable tool 10 is assembled, thecover piece 160 rides on the middle section 147 of the slotted piece 142of the second housing cover 140 the range of motion of the cover section160 is also determined by the top and bottom faces 152, 154 of thesecond housing cover 140.

FIG. 10 shows the cover section 160 positioned within the pivot housing100 when the head section 12 is in-line with the body section 14. FIG.11 shows the cover section 160 assembled with the second housing cover140 and the pivot housing 100 in the same position. As seen in FIG. 10,the bottom edge 164 of the cover section 160 contacts the first face 212of the pivot housing 100. As seen in FIG. 11, the top edge 165 of thecover section 160 contacts the top face 152 of the second housing cover140. These contact points retain the cover section 160 in the requiredposition to protect the internal components of the handheld pivotabletool 10.

FIG. 12 shows the cover section 160 with respect to the pivot housing100 when head section 12 is pivoted to an intermediate position betweena position where the head section 12 is in-line with the body section 14and a position where they are perpendicular to each other. FIG. 13 showsthe cover section 160 with respect to the second housing cover 140 andthe pivot housing 100 in the same orientation. In intermediateorientations of the head section 12 with respect to the body section 14,the cover section 160 does not contact either the first or second faces212, 214 of the pivot housing 100 or the top or bottom faces 152, 154 ofthe second housing cover 140. Therefore, the cover section 160 is freeto move with respect to both the second housing cover 140 and the pivothousing 100 as constrained by the faces, and the cover section 160 willcover the internal components of the handheld pivotable tool 10regardless of the position of the cover section 160.

FIG. 14 shows the cover section 160 with respect to the pivot housing100 when the head section 12 is at an approximate 65 degree angle withrespect to the body section 14. FIG. 15 shows the cover section 160 withrespect to the second housing cover 140 and the pivot housing 100 in thesame orientation. As shown in FIG. 14, the top edge 165 of the coversection 160 contacts the second face 214 of the arcuate slot 210 of thepivot housing 100. As shown in FIG. 15, neither the top nor the bottomedges 165, 164 of the cover section 160 contacts the top or bottom faces152, 154 of the second housing cover 140. Therefore, with additionalpivoting of the head section 12 with respect to the body section 14, thecover section 160 will move counter-clockwise (as seen in the view ofFIG. 14) closer to the position where its bottom edge 164 engages thebottom face 154 of the second housing cover 140.

FIG. 16 shows the cover section 160 with respect to the pivot housing100 when the head section 12 is perpendicular to the body section 14.FIG. 17 shows the cover section 160 with respect to the second housingcover 140 and the pivot housing 100 in the same orientation. As shown inFIG. 17 the bottom edge 164 of the cover section 160 is engaged with thebottom face 154 of the second housing cover 140.

A third embodiment of the handheld pivotable tool 10 is shown in FIGS.22-26. In this embodiment, the head section 12 rotates with respect tothe longitudinal axis of the body section 14. The position of thespindle lock housing (not shown in FIGS. 22-26, the spindle lock housingin this embodiment is similar to that shown in described in previousembodiments) and the pivot housing 100, however can be modified (asshown in FIG. 22) so the output shaft is offset from the center of thepivot housing 100 because of the formation of the universal joint 80with three sections. This offset positioning allows the output tool (notshown) to be operated in tight spaces. For example, because the spindleis positioned closer to one outside surface of the head section 12, thehandheld pivotable tool 10 can be operated to drill a hole or insert afastener located closer to a wall than would be possible if the spindlewas positioned at the center of the pivot housing 100.

In this embodiment, the gearbox housing 40 is formed as a separatemember from the lock housing 60. The gearbox housing 40 is slightlyaltered as discussed herein (although it is modified in a way that willnot hinder performance of the embodiments discussed above). As shown inFIG. 23, the top surface 45 of the shoulder 44 includes a plurality offlanges 324 that project upwards into the neck 46 of the gearbox housing40. The flanges 324 may be equally spaced around the circumference ofthe gearbox housing 40. Preferably, the gearbox housing 40 includes fourflanges 324 spaced ninety degrees apart. In some embodiments, theflanges 324 can be formed as rectangular blocks, in other embodiments,the flanges 324 can be formed as different shapes. The shoulder 44 alsoincludes two grooves 352 around the circumference of the shoulder 44that accept two retaining rings 350, which are discussed below.

The lock housing 60 is also slightly modified from the structurediscussed above (although it is modified in a way that will not hinderperformance of the embodiments discussed above). In embodiments that donot include structure to allow the head section 12 to pivot with respectto the body section 14, a cylindrical sleeve is provided that surroundsthe neck 46 of the gearbox housing 40 and can move axially about thegearbox housing 40. This sleeve is formed with the structure of the lockhousing 60 disclosed specifically with this embodiment. For simplicity,only the lock housing 60 is discussed here (and shown in the figures),but the reference to the lock housing 60 should be interpreted to alsorefer to a sleeve with the specific structure discussed herein.

The lock housing 60 includes a cam surface 310 (best shown in FIG. 25)formed around the outer surface of the lock housing 60. The cam surface310 is formed as an inclined plane that wraps around a substantialportion of the circumference of the lock housing 60 starting at thebottom edge. As shown in FIG. 24, the lock housing 60 also includes aplurality of recesses 316 formed on the bottom edge. Desirably, therecesses 316 are equally spaced at uniform positions around the innercircumference of the lock housing 60. The recesses 316 are sized andpositioned to engage the flanges 324 when the lock housing 60 engagesthe upper surface of the shoulder 44 of the gearbox housing 40. In oneembodiment, the lock housing 60 includes twice the number of recesses316 than the number of flanges 324 formed in the gearbox housing 40. Inother embodiments, the lock housing 60 can have the same number ofrecesses 316 as flanges 324, or a greater number of recesses 316 toflanges 324.

The handheld pivotable tool 10 also includes a swivel cap 330 formedfrom an upper cap 342 and a lower cap 332, as best seen in FIG. 22. Theswivel cap 330 is rotatably connected to the shoulder 44 of the gearboxhousing 40 with two retaining rings 350 placed above and below the lowercap 332 and tightened to engage each of the grooves 352 in the shoulder44. As shown in FIG. 26, the upper cap 342 has a cam surface 344 thatopposes the cam surface 310 on the lock housing 60. The cam surface 344of the upper cap 342 is formed on the lower surface of the upper cap342.

When the handheld pivotable tool 10 is assembled, the upper cap 342 ispositioned such that it is above the cam surface 310 of the lock housing60, which allows the cam surface 344 on the upper cap to engage the camsurface 310 on the lock housing 60. The upper and lower caps 342, 332are connected with fasteners (not shown) that extend through holes inthe respective caps 342, 332 so that the upper cap 342 and the lockhousing 60 are positioned with respect to the gearbox housing 40. FIGS.7-9 show the upper and lower swivel caps 342, 332 positioned on thehandheld rotary tool 10 with respect to the lock housing 60 and thegearbox housing 40. A spring 336 (best seen in FIG. 22) is providedwithin the swivel cap 330 between the lower cap 332 and the lowersurface 315 of the lock housing 60 to push the lock housing upwards awayfrom the lower cap 332.

In operation, rotation of the swivel cap 330 moves the lock housing 60with respect to the gearbox housing 40. For example, when the swivel capis rotated clockwise the cam surface 344 of the upper cap 342 engagesthe cam surface 310 of the lock housing, which forces the lock housing60 downward against the biasing force of the spring 336. With sufficientclockwise rotation, the lock housing 60 is moved far enough downward sothat the flanges 324 of the gearbox housing 40 are inserted into therecesses 316 of the lock housing. Because the flanges 324 are positionedwithin the recesses 316, the lock housing 60 and the head section 12 areselectively positioned and cannot rotate with respect to the bodysection 14.

When the swivel cap 330 is rotated in the counter-clockwise directionwith respect to the body section 14, the lock housing 60 moves upwarddue to the biasing force of the spring and releases the engagementbetween the cam surfaces 310, 344. The upward movement of the lockhousing 60 causes the flanges 324 to disengage the recesses 316 of thelock housing 60, so that the lock housing 60 and the head section 12 canrotate with respect to the body section 14. When the head section 12 isin the desired orientation with respect to the body section 14, theswivel cap 330 is rotated clockwise to engage the flanges 324 with therecesses 316 in the lock housing, which prevents rotation of the headsection 12 with respect to the body section 14.

Alternatively, other structures that are known to those of skill in theart can be used to selectively secure the lock housing 60 to the gearboxhousing 40 to prevent the head section 12 from rotating with respect tothe body section 14 when the head section 12 is in a position selectedby the user.

Each of the embodiments discussed above may include a clutch 16 thatallows the maximum output torque of the torque to be selected by theuser. Clutch designs that are known by those of skill in the art may beused in conjunction with these embodiments to allow selection of amaximum output torque of the tool. Additionally, a suitable clutchdesign, for use with the handheld pivotable tool 10 is described in U.S.Ser. No. 11/090,947, which is fully incorporated herein by reference.

It is therefore intended that the foregoing detailed description beregarded as illustrative rather than limiting, and that it be understoodthat it is the following claims, including all equivalents, that areintended to define the spirit and scope of this invention.

1. A rotary tool operable in at least two positions comprising: (a) a transmission with an input end and an output end; (b) a body section housing the input end of the transmission and a motor that is connected to the input end of the transmission, the body section including a longitudinal axis; (c) a head section housing the output end of the transmission and a spindle that is connected to the output end of the transmission; and (d) a lock to selectively retain the head section in a selected orientation with respect to the body section along a pivot axis, wherein the head section is capable of being retained substantially orthogonally to the longitudinal axis of the body section.
 2. The tool of claim 1 wherein the lock comprises a lock housing that is positioned within the body section, and a pivot housing within the head section and pivotable with respect to the lock housing about the pivot axis.
 3. The tool of claim 2 wherein each of the lock housing and the pivot housing include apertures, and the lock further comprises a block retained in the lock housing aperture and selectively positioned in the pivot housing aperture to retain the head section in the selected orientation with respect to the body section.
 4. The tool of claim 3 wherein the block may be disengaged from the pivot housing aperture to pivot the head section with respect to the body section.
 5. The tool of claim 3 wherein the head section may be perpendicular to the body section when the block is in the pivot housing aperture.
 6. The tool of claim 3 wherein the block includes a plurality of radially extending arms.
 7. The tool of claim 6 wherein the plurality of radially extending arms are each perpendicular to adjacent arms.
 8. The tool of claim 7 wherein the pivot housing aperture is provided with a number of slots that is greater than the number of arms on the block.
 9. The tool of claim 8 wherein the pivot housing aperture is provided with twice the number of slots than the number of arms on the block.
 10. The tool of claim 8 wherein the head section can be selectively retained is at an approximate forty-five degree angle with respect to the body section when the block is in the pivot housing aperture.
 11. The tool of claim 3 further comprising a spring positioned between the lock housing and the block to bias the block into the pivot housing aperture.
 12. The tool of claim 3 wherein the body section further comprises a second housing that surrounds a majority of the lock housing and the transmission, with a majority of the second housing being surrounded by the pivot housing.
 13. The tool of claim 12 further comprising a cover plate movably positioned between the second housing and the pivot housing.
 14. The tool of claim 13 wherein the pivot housing forms an arcuate slot with a first stop and a second stop establishing the limits of the slot, and the outer surface of the second housing includes an upper edge and a lower edge, wherein the range of motion of the cover plate is defined by the arcuate slot and the upper and lower edges.
 15. The tool of claim 14 wherein the second housing and the cover section enclose the lock housing and the transmission in each orientation of the head section.
 16. The tool of claim 13 wherein the second housing is generally spherical, the cover plate is generally arcuate, and a portion of the pivot housing that surrounds the cover plate and second housing is generally spherical.
 17. The tool of claim 1 wherein the transmission comprises a universal joint.
 18. The tool of claim 17 wherein the universal joint is formed of a first section, a second section pivotably connected to the first section, and a third section pivotably connected to the section, wherein the first section cooperates with the input end and the third section cooperates with the output end.
 19. The tool of claim 2 further comprising a gearbox housing within the body section supporting the motor and the input end of the transmission, wherein the head section is rotatable about the longitudinal axis of the body section, the lock housing being selectively engageable with the gearbox housing to prevent the head section from rotating with respect the body section.
 20. The tool of claim 19 further comprising a rotatable cap formed on the body section to control engagement between the lock housing and the gearbox housing.
 21. The tool of claim 20 further comprising a plurality of flanges that project from the gearbox housing.
 22. The tool of claim 21 wherein the lock housing includes a plurality of recesses that accept the plurality of flanges.
 23. The tool of claim 20 further comprising a cam surface at a bottom end of the lock housing and a corresponding cam surface on the rotatable cap.
 24. A tool with a rotatable head section comprising: (a) a transmission with an input end connected to a rotating member and an output end connected to an output tool; (b) a body section that retains an input end of the transmission and includes a gearbox housing and a longitudinal axis; (c) a sleeve that surrounds a top portion of the gearbox housing and is movable along the gearbox housing; (d) a rotatable cap surrounding the sleeve to selectively cause engagement of the sleeve and the gearbox housing; (e) a head section that houses an output of the transmission, and that is rotatable about the body section along the longitudinal axis of the body section, wherein the head section is prevented from rotating with respect to the body section when the sleeve engages the gearbox housing.
 25. The tool of claim 24 further comprising a plurality of flanges that project from the gearbox housing.
 26. The tool of claim 25 wherein the sleeve includes a plurality of recesses that accept the plurality of flanges to cause engagement of the sleeve and the gearbox housing.
 27. The tool of claim 26 wherein the number of the plurality of recesses is the same as the number of flanges.
 28. The tool of claim 25 wherein the number of the plurality of recesses is a positive multiple of the number of flanges.
 29. The tool of claim 24 further comprising a cam surface at a bottom end of the sleeve and a corresponding cam surface on the rotatable cap.
 30. The tool of claim 24 further comprising: (a) a plurality of flanges that project from the gearbox housing; (b) a plurality of recesses provided on a bottom surface of the sleeve to accept the plurality flanges; (c) a cam surface at the bottom end of the sleeve; and (d) a cam surface on the rotatable cap, wherein the cap can be rotated to cause engagement between the cam surfaces to cause the recesses in the sleeve to engage the flanges in the gearbox housing.
 31. The tool of claim 30 wherein the sleeve is biased away from engagement with the gearbox housing.
 32. A tool operable in at least two positions comprising: (a) a transmission with an input end and an output end; (b) a body section with a longitudinal axis including: (i) a gearbox housing, (ii) a lock housing that surrounds a top portion of the gearbox housing and that can move along the gearbox housing, (iii) a motor, (iv) a rotatable cap surrounding a bottom portion of the lock housing to selectively cause engagement between the lock housing and the gearbox housing; (c) a head section rotatably connected to the body section to rotate about the longitudinal axis of the body section, with the head section being prevented from rotating with respect to the body section when the lock housing engages the gearbox housing; (d) a pivot housing disposed between the head section and the body section and being pivotably connected to the lock housing about a pivot axis, wherein each of the pivot housing and the lock housing include an aperture; and (e) a block positioned in the lock housing aperture and selectively inserted in the pivot housing aperture to retain the head section in a selected orientation with respect to the body section. 